EDT Electrodes. Electrodes for all EDT Machines

Transcription

1 EDT Electrodes Electrodes for all EDT Machines

2 About Us Udo Plante GmbH is among the leading global manufacturers of electrodes for roll texturing machines. Your customers have a variety of requirements for the surface properties of their metal sheets. These properties are the most important aspect of the sheets, and they are determined by the texture of your rolls. Roll texture determines the surface structure and the roughness of the metal sheet. The type of electrode in the EDT machine determines the quality of this texture. We have been supplying high quality electrodes to renowned operators of EDT machines since Our product portfolio includes hollow profile copper (CE), bar (PE), and graphite (GE) electrodes in a variety of dimensions and metallurgies. Publication of the photo with the kind permission of H. Kleinknecht & Co. GmbH 2

3 Our Offers Page 4 CE Electrodes Hollow profile copper electrodes for Waldrich and Kleinknecht EDT machines Page 4 CE Electrodes with seals Page 6 IN Electrodes Hollow profile copper electrodes for Ingersoll EDT machines Page 8 GE Electrodes Graphite electrodes for all EDT machines Page 10 PE Electrodes Bar electrodes for Sarclad and Herkules EDT machines Page 12 Accessories for all EDT machines 3

4 CE Electrodes Udo Plante GmbH supplies hollow profile copper electrodes in all required lengths for EDT machines produced by Herkules, Kleinknecht, and Waldrich Siegen. Electrodes for EDT machines are normally made of the material E-Cu. Highly sensitive texturing procedures can benefit from higher quality materials, such as SE-Cu or OF-Cu. All CE electrodes are stamped with the UP logo. Seals Optionally we offer two different seals for hollow profile copper electrodes. CE2 bonded polyurethane seal 2 C E CE1 plug-in NB reusable rubber seal 4

5 CE Electrodes Accessories see page 12 3 Performance Levels Udo Plante GmbH offers three levels of electrode performance to fulfill any roll texturing requirement. The electrode performance is matched to the sensitivity of the EDT process and the quality requirements of the customer. Standard Performance 1CE 1CE electrodes are made of copper produced by electrolytic refining and contain oxygen, with a high conductivity of 57 m/ω mm² as a minimum. Advanced Performance 2CE 2CE electrodes are made of ultra pure, deoxidized copper with a low residual phosphorus content and a high conductivity of 58 m/ω mm² as a minimum. High Performance 3CE 3 CE electrodes consist of ultra pure, non-deoxidized, oxygen-free copper containing no elements that can be vaporized under vacuum, and have a high conductivity of up to 59 m/ω mm² as a minimum. Electrode lengths CE hollow profile copper electrodes are available in all required lengths. Our stock material Ordering number Seal Material Width in mm Length in mm 1CE E-Cu CE E-Cu CE2110 CE2 E-Cu CE E-Cu CE E-Cu CE E-Cu CE E-Cu CE SE-Cu CE2150 CE2 SE-Cu

6 IN Electrodes IN electrodes are made from blocks of one of several types of ultra pure copper, either E-Cu, SE-Cu, or OF-Cu. These copper blocks are hot extruded to create a precise profile, resulting in the shape of the IN electrode. This procedure makes it possible to produce a homogeneous structure free from air, oxide or slag inclusions, gas bubbles, or other inhomogeneities. Such impurities could drastically affect the electrical conductivity at different points, which could have adverse effects on the texturing results and lead to banding. Conventional electrodes from other suppliers are made by using a powder-metallurgical procedure. In this procedure, copper powder of a certain grain size is brought into a mold under high temperature and high pressure and sintered under inert gas conditions (Hot Isostatic Pressing- HIP) dimensionally stable seal 6

7 IN Electrodes Accessories see page 12 IN Electrodes Powder-metallurgical electrodes Material ultra pure copper sintered E-Cu, SE-Cu or OF-Cu copper powder Structure Homogenous Nonhomogenous Free from air and slag inclusions, gas bubbles and other nonhomogeneities Specific weight (in kg/dm³) A difference in compression will result in different burn-off during the EDT procedure Weight per electrode (in g) Conductivity (in m/ω mm²) min *for same size 1IN Good Reasons why you should prefer IN electrodes to conventional powder-metallurgically produced electrodes: Fewer electrode changes due to a more than 30% longer lifetime Higher process safety due to electrodes with a homogeneous structure Lower losses due to 62% more electrical conductivity Higher quality for the EDT procedure due to a more even electrode burn-off Conclusion: Due to their homogenous structure, IN electrodes minimize the risk of banding on rolls. Compared to conventional powder-metallurgically produced electrodes, a more even burn-off is always guaranteed. Our stock material Ordering number Seal Material Width in mm Length in mm 1IN dimensionally stable seal E-Cu IN dimensionally stable seal SE-Cu IN dimensionally stable seal E-Cu IN dimensionally stable seal SE-Cu

8 GE Electrodes Sockets and other accessories see page 12 As a leading manufacturer of EDT electrodes, we offer isostatically pressed graphite electrodes for use in roll texturing machines. Thanks to a targeted raw material selection performed according to the most demanding criteria, and due to application-specific comparative tests, we can offer EDT graphite electrodes with consistent quality and a high level of performance. 1GE0100 Pure graphite electrode of Plangraph 1 2GE Graphite electrode with a copper content of 28% of Plangraph 2 2GE Graphite bar electrode with a copper content of 28% of Plangraph 2 with M6x20 internal thread 2GE Graphite bar electrode with a copper content of 28% of Plangraph 2 with shaft Our stock material Ordering number Metal content Material Dimensions Bore Length in % in mm in mm in mm 1GE Plangraph 1 45x GE Plangraph 2 45x GE Plangraph 2 Ø GE Plangraph 2 Ø GE Plangraph 2 Ø8 Ø

9 Climbing the Highest Peaks A comparative test between copper and graphite electrodes shows the difference among the peak densities for a given roughness (Ra value). Comparison of electrode types: 2CE2150 Hollow profile copper 1GE0100 Plangraph 1 (solid graphite) 2GE Plangraph 2 (72% graphite/28% copper) The result The hollow profile copper electrodes achieve a peak density of only 63 peaks per cm in Cap (-) mode with a roughness of approx. 3.0 µm Ra. In the same mode, Plangraph 1 electrodes (solid graphite) can achieve a much greater peak density of 104 peaks per cm. Plangraph 2 electrodes (72% graphite/28% copper) produce an even higher peak density of 120 peaks per cm. Overview Electrode Mode Roughness in µm Ra Peak number in units/cm 2CE2150 Cap(-) Hollow copper profile 2CE2150 Impulse(+) Hollow copper profile 1GE0100 Cap(-) Plangraph 1 2GE Cap(-) Plangraph 2 9

10 PE Electrodes Udo Plante GmbH supplies bar electrodes in all required lengths for EDT machines made by Herkules and Sarclad. Bar electrodes are manufactured from specially modified alloys with tight machining analysis tolerances. These tolerances are guaranteed according to DIN EN ISO Further mechanical processing is performed on modern CNC machines according to the DIN EN ISO 9002 quality management system. Electrodes for Sarclad and Herkules EDT machines can be supplied in any lengths and diameters required for your installation. 10

11 PE Electrodes Sockets and other accessories see page 12 Higher requirements higher quality The insulating protective coating is made of a flexible, transparent insulating varnish consisting of modified silicone resin. Trust is a good thing control is a better one The protective varnish can be seen under UV light in order to check the homogeneity of the coating Protective varnish coating under UV light Uncoated contact surface Shorter installation time due to user-friendly packaging Bar electrodes are supplied on plug boards in a packaging unit of 72 units. This ensures easy handling during the installation into the machine as well as effective protection of the electrodes and the insulating varnish against damage during transport. Our stock material Ordering number Protect varnish Material Diameter in mm Length in mm 4PE PE3 Special alloy PE PE3 Special alloy

12 Accessories In addition to our electrode portfolio, we can offer you a multitude of accessories for your EDT machine.the following is a selection of our most common accessories. UP Socket Threaded clamping bush for bar electrodes UP Insulation Shell Matching insulation cap for socket and bar electrode in lengths of 37.2 mm and 29.3 mm CE1 Seal Plug-in reusable rubber seal UP Bellows High quality bellows for all frame dimensions Images are not true to scale 12

13 Accessories UP Seals Gasket Roll seals of all shapes and sizes UP Flexible Connectors Flexible connectors in all desired lengths and with all required connection bores. UP Servo Rods Servo rods for electrode holders Images are not true to scale 13

14 Materials, Dimensions and weight Hollow profile copper electrodes CE/IN, Cu qualities Materials overview All CE and IN copper hollow profiles are extruded and drawn. All materials are free from beryllium. 1 CE/1 IN 2 CE/2 IN 3 CE/3 IN Designation previous E-Cu SE-Cu OF-Cu new Cu-ETP Cu-HCP Cu-OFE Material number CR021A CR009A electrical conductivity m Ω mm² min. 57 min. 58 min. 59 min. Cu content in % 99.90¹ 99.95¹ 99.99¹ Dimensions CE in mm 45x12x4xLength Dimensions IN in mm 75x16x5.5xLength 72x16x5.5xLength Length CE Weight² in g/unit 100 mm mm mm mm mm 487 Bar electrodes PE Material overview 4 P E Material Physical properties Copper alloy Density kg 8.8 dm³ Melting range C Elasticity module kn mm² 115 Thermal conductivity W m K 75 Elongation 1 coefficient K Electrical m conductivity Ω mm² Specific electrical Ω mm² resistance m Length IN Weight² in g/unit 102 mm 620³ ¹ incl. Ag ² approx. weight ³ excluding weight of cutout Length tolerance +1-0 mm cut at right angle and cleanly deburred Graphite electrodes GE Plangraph Graphite electrodes for roll texturing machines Plangraph 1 Plangraph 2 Performance A- A Grain size (µ) > Yield strength (N/mm²) Specific resistance (µ Ω m) Metal content % 0 28 Specific weight (kg/dm³) The physical data listed for each Plangraph material are approximate values that are not binding. 14

15 Our Partner H. KLEINKNECHT & Co. GmbH, a renowned electrical equipment manufacturer from Siegen, Germany, has been designing and implementing electrical equipment and technological control systems for roll grinding machines and roll texturing machines for decades. They have equipped and modernized more than 60 EDT machines all over the world with new electrical control systems and generators. More than 2,600 EDT generators are in use every day in the roll industry and have proven to be extremely stable. With the ambition to create more of their own equipment, KLEINKNECHT developed their own high end roll texturing machine, based on their long-standing experience in the area of roll surface treatment, which offers a multitude of innovative and patented new features. Highly modern linear motor technology is used for electrode adjustment, ensuring the highest possible gap control accuracy over the entire electrode stroke. The positioning of the individual eroding axes for a fast spark transmission is achieved with the use of a very sensitive gap voltage control system (GAP-Voltage-Control), developed by KLEINKNECHT itself, separate from the spark generator. With its innovative ideas, the new KLEINKNECHT EDT machine has made the known weak points of conventional EDT machines a thing of the past. KLEINKNECHT has been active in the area of roll grinding machines for more than 60 years. More than 1,000 control systems for roll grinding machines have been delivered. Of these, more than 300 are CNC-based systems for new and modernized machines. Today, the KLEINKNECHT GPC2 control system can be found on roll grinding machines H. Kleinknecht & Co. GmbH Eiserntalstraße Siegen-Eisern Germany Phone: Fax: vertrieb@kleinknecht.de from Waldrich Siegen, Herkules, Meuselwitz, Naxos, Lynson, and other manufacturers. In the last few years, KLEINKNECHT has become a one-stop solution for complex retrofits and modernizations of roll grinding machines. Today, KLEINKNECHT can service not only the electrical components of roll grinders, but also all their mechanical aspects. Operators of roll grinding machines and EDT machines can rely on first-class service as well as on a safe long-term spare parts supply. Furthermore, Udo Plante GmbH and KLEINKNECHT have cooperated in the field of electrode development for EDT machines for many years. 15

16 How to Reach Us Udo Plante GmbH Angermunder Straße 270d Duisburg Germany Phone: Fax: American Anodes LLC 8141 Technology Drive Covington, GA USA Phone: Toll free: Your sales partner: